The present invention relates to a metal card manufacturing method including the steps of: preparing a metal sheet having a given size capable of accommodating a plurality of individual cards; preparing a ferromagnetic insulating sheet made by containing epoxy in a ferrite to the same size capable of accommodating the plurality of individual cards as the metal sheet; preparing an inlay sheet on which antenna coils are printed to the same size as the insulating sheet and forming holes on at least one or more edges of stacked sheets formed by stacking a plurality of sheets inclusive of the insulating sheet and the inlay sheet; fitting the holes formed on the stacked sheets to pins located on a loading plate; placing the metal sheet on top of the stacked sheets; forming a metal card sheet through lamination among the metal sheet and the stacked sheets; and cutting the metal card sheet along individual card outlines of the plurality of individual cards.
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2. The metal card manufacturing method according to claim 1, wherein the forming holes on at least one or more edges of the stacked sheets comprises step of punching the holes on positions adjacent to peaks at which the two or more edges of the stacked sheets meet.
This invention relates to a method for manufacturing metal cards, such as credit cards or identification cards, with improved structural integrity and alignment during production. The method addresses the challenge of maintaining precise alignment and preventing misalignment or deformation of stacked metal sheets during the manufacturing process, particularly when forming holes for attachment or functional purposes. The method involves stacking multiple metal sheets to form a layered structure. Holes are then punched on at least one or more edges of the stacked sheets. Specifically, the holes are formed at positions adjacent to the peaks where two or more edges of the stacked sheets meet. This strategic placement of holes helps to maintain alignment and stability during subsequent processing steps, such as cutting or bending, by reinforcing the edges where misalignment is most likely to occur. The punched holes may also serve functional purposes, such as accommodating fasteners or connectors. The method ensures that the metal sheets remain properly aligned throughout the manufacturing process, reducing defects and improving the quality of the final metal cards. The technique is particularly useful in high-precision applications where dimensional accuracy is critical.
3. The metal card manufacturing method according to claim 2, further comprising step of replacing the cutting tool with a new one when cutting operations for the individual card outlines are performed over a predetermined number of times set in advance.
The invention relates to a method for manufacturing metal cards, such as credit or identification cards, where the cards are cut from a metal sheet using a cutting tool. The problem addressed is the wear and degradation of the cutting tool over time, which can lead to reduced cutting precision and quality. To maintain consistent cutting performance, the method includes a step of automatically replacing the cutting tool with a new one after the tool has been used for a predetermined number of cutting operations. This ensures that the tool remains sharp and precise, preventing defects in the card outlines. The method may also involve pre-processing steps, such as forming a metal sheet into a desired shape and thickness, and post-processing steps, such as deburring or polishing the cut edges. The replacement step is triggered based on a predefined threshold, which is determined based on the tool's expected lifespan and the material being cut. This approach improves manufacturing efficiency and product quality by minimizing tool-related errors.
5. The metal card manufacturing method according to claim 4, wherein the providing the metal sheet further comprises step of inserting machined layers made of a plastic material into the insertion spaces.
This invention relates to a method for manufacturing metal cards, such as credit cards or identification cards, with enhanced durability and functionality. The method addresses the problem of metal cards being prone to bending, cracking, or failing under stress due to their rigid and uniform structure. The solution involves creating a metal card with a layered construction that includes both metal and plastic components to improve flexibility and performance. The method begins by providing a metal sheet with a predetermined thickness and dimensions. The metal sheet is then processed to form insertion spaces, which are cavities or recesses within the metal structure. These spaces are strategically placed to allow for the integration of additional materials. Machined layers made of a plastic material are then inserted into these insertion spaces. The plastic layers serve to reinforce the metal card, distribute stress more evenly, and prevent cracking or bending. The plastic material may also be chosen for its specific properties, such as flexibility, impact resistance, or compatibility with electronic components. The resulting metal card combines the aesthetic and durability benefits of metal with the functional advantages of plastic, making it more resistant to everyday wear and tear while maintaining a premium appearance. This hybrid construction allows for greater design flexibility and improved performance in real-world applications.
6. The metal card manufacturing method according to claim 5, wherein the providing the metal sheet further comprises step of forming machined layer exposure portions on an opposite side surface to the metal sheet side on which the machined layers are inserted.
This invention relates to a method for manufacturing metal cards, such as credit cards or identification cards, with enhanced durability and aesthetic features. The method addresses the challenge of creating metal cards that have both functional and decorative elements while maintaining structural integrity. The process involves forming machined layers on one side of a metal sheet, which are then used to create intricate designs or functional features. Additionally, the method includes forming machined layer exposure portions on the opposite side of the metal sheet, allowing for the integration of additional components or visual effects. These exposure portions may be used to expose underlying layers, embed electronic components, or create unique visual patterns. The technique ensures precise alignment and secure bonding between the machined layers and the metal sheet, resulting in a high-quality, durable metal card. The method is particularly useful in applications where both functionality and aesthetics are critical, such as premium credit cards or high-security identification cards. The process may also include steps for finishing the card, such as polishing or coating, to enhance its appearance and longevity.
7. The metal card manufacturing method according to claim 6, wherein the cutting the metal card sheet further comprises step of cutting chip exposure areas having a smaller width than the machined layer exposure portions and located inside the individual card outlines to allow the antenna coils of the inlay sheet to be exposed to an outside.
This invention relates to a method for manufacturing metal cards, specifically addressing the challenge of integrating antenna coils within metal card structures while ensuring proper exposure for functionality. The method involves cutting a metal card sheet to form individual card outlines, with a focus on creating chip exposure areas. These areas are narrower than the machined layer exposure portions and are positioned inside the card outlines. The purpose of these chip exposure areas is to allow the antenna coils embedded in the inlay sheet to be exposed to the outside, ensuring proper communication and functionality of the card. The process includes precise cutting to maintain structural integrity while enabling the necessary exposure for the antenna coils. This method is particularly useful in applications where metal cards require embedded electronics, such as payment cards or identification cards, where signal transmission through the metal material is critical. The invention ensures that the antenna coils remain accessible despite the metal enclosure, solving a common issue in metal card manufacturing where metal can interfere with wireless communication. The method is designed to be efficient and scalable, suitable for mass production of metal cards with embedded electronics.
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June 20, 2018
May 28, 2024
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